Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Drive Axle/HalfShafts

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REMOVAL & INSTALLATION



The halfshaft consists of a Double Offset Joint (DOJ), an axle shaft, a constant velocity joint, and a stub axle.

ff-1 and 1300G Models


Click image to see an enlarged view

Fig. Fig. 1 Exploded view axle shaft assembly-ff-1 and 1300G models with drum brakes



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Fig. Fig. 2 Exploded view axle shaft assembly-ff-1 and 1300G models with disc brakes

  1. Engage the parking brake. Remove the wheel cover and loosen the lug nuts.
  2.  
  3. Flatten the lockplate on the hub nut and loosen the hub nut.
  4.  
  5. Raise the car and support it with jackstands.
  6.  


CAUTION
Be sure that the car is securely supported.

  1. Remove the lug nuts, wheel and tire.
  2.  
  3. Remove the hub nut.
  4.  
  5. Remove the 3 retaining bolts and separate the double offset joint from the brake drum.
  6.  
  7. Remove the inner panel from the wheel well.
  8.  
  9. Turn the steering knuckle to full lock and pull the stub axle out of the hub.
  10.  
  11. Slide the drive axle assembly out of the wheel well.
  12.  



Click image to see an enlarged view

Fig. Fig. 3 Axle shaft components-ff-1 and 1300G models

To install:

  1. Reverse the above process and assemble the drive axle to the vehicle.
  2.  
  3. Tighten the hub nut to 87-101 ft. lbs. (117-136 Nm) and secure it by bending the tabs of the lockplate up around it.
  4.  


CAUTION
Excessive torque applied to the hub nut will cause bearing damage.

Except ff-1 and 1300G Models
  1. Engage the parking brake.
  2.  
  3. Remove the wheel cover (sedans and wagon), and loosen the lug nuts.
  4.  
  5. Raise the car and support it with jackstands.
  6.  


CAUTION
Be sure that the car is securely supported.

  1. Remove the lug nuts, wheel and tire.
  2.  
  3. Remove the drum brake or disc brake rotor as outlined in .
  4.  
  5. On drum brake equipped cars, remove the 4 backing plate installing bolts and safety wire the backing plate to the suspension without disconnecting the hydraulic line.
  6.  


WARNING
Remove the bracket which secures the brake hose to the shock absorber strut in order to gain enough free movement of the hose to perform Step 5.

  1. Drive out the spring pin, which fastens the double offset joint end of the axle shaft to the driveshaft, by lightly tapping the pin out with a hammer. Throw the old spring pin away. Do not reuse it.
  2.  
  3. Remove the self locking nuts which attach the ends of the control arm to the stabilizer bar and the crossmember inner pivot.
  4.  
  5. Separate the control arm from the crossmember pivot by prying it rearward with a suitable lever.
  6.  
  7. To disconnect the control arm from the stabilizer bar, swing the link forward.
  8.  
  9. Pull the axle shaft out of the driveshaft (double offset joint side) by pushing outward on the front suspension assembly.
  10.  


WARNING
Be careful not to damage the boots on the double offset and constant velocity joints.

  1. Remove the other end of the drive axle out of the housing, while holding the shaft so that it doesn't drop. Do not hammer on the end of the drive axle to remove it. Damage to both the bearing and the splines will result.
  2.  

To install:

  1. Thread a suitably sized metric bolt or rod, which is long enough to fit through the axle housing, into the end of the stub axle.
  2.  
  3. Fit the bolt through the axle housing, using care not to damage the oil seal, splines, or the bearing. Draw the drive axle assembly into place by grasping the end of the bolt with a puller.
  4.  
  5. On GL Coupes, install the brake disc and hub, as outlined in .
  6.  
  7. On drum brake equipped models, perform the following steps:
  8.  
    1. Secure the backing plate with its 4 bolts. Tighten the bolts to 22-37 ft. lbs. (29-50 Nm) each.
    2.  
    3. Install the brake drum assembly as detailed in .
    4.  

  9. Install the hub nut:
  10.  
    1. On 1972-73 models, install the spacer, lockwasher, and hub nut.
    2.  
    3. Tighten the nut to 145-181 ft. lbs. (196-245 Nm) and secure it with the lockwasher.
    4.  
    5. On 1974-84 models, install the spacer, conical spring washer and the hub nut.
    6.  
    7. Tighten the nut to 160-180 ft. lbs. (216-244 Nm), (174 ft. lbs. (244 Nm) preferred).
    8.  
    9. Secure the hub nut to the axle shaft by using a punch to stake the flange on the nut to the groove in the end of the axle shaft.
    10.  

  11. Connect the double offset joint side of the axle shaft to the driveshaft and secure them with a new spring pin.
  12.  
  13. Fit the washer and bushing over the end of the stabilizer bar and then connect the transverse link to the end of the stabilizer.
  14.  
  15. Install the remaining washer and bushing and temporarily secure them with a new self-locking nut.
  16.  
  17. Install the control arm to the crossmember pivot in the same way it was attached to the stabilizer bar in Step 7. Temporarily secure them with another new self-locking nut.
  18.  
  19. On disc brake models, install the dust cover, caliper, and parking brake cable, as detailed in .
  20.  
  21. Install the wheel with the lug nuts, remove the jackstands, and lower the car to the ground.
  22.  
  23. Tighten the new self-locking nuts used at each end of the transverse link to 72-87 ft. lbs. (97-117 Nm) with the car resting on its wheels.
  24.  

CV-JOINT OVERHAUL



  1. Remove the bands from the boots at both the constant velocity and double offset joints, and slide the boots away from the joints.
  2.  
  3. Pry the circlip out of the double offset joint, and slide the outer race of the joint off the shaft.
  4.  
  5. Remove the balls from the cage, rotate the cage slightly, and slide the cage inward on the axle shaft.
  6.  



Click image to see an enlarged view

Fig. Fig. 4 Pry up on the outer band of the CV-boot



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Fig. Fig. 5 Use pliers to remove the inner band from the CV-boot

  1. Using snapring pliers, remove the outer snapring which retains the inner race to the shaft.
  2.  
  3. Slide the inner race, cage, and boot off the axle shaft.
  4.  


WARNING
Exercise care to avoid damaging the boot on the inner snapring.

  1. Pull back the constant velocity joint boot and pivot the stub axle around the joint far enough to expose a ball.
  2.  
  3. Remove the exposed ball, and continue this procedure until all balls are removed, at which time the outer race (stub axle) may be removed from the axle shaft.
  4.  
  5. Remove the retaining snapring, and slide the inner race off the shaft.
  6.  
  7. Inspect the parts of both joints for wear, damage, or corrosion, and replace if necessary. Examine the axle shaft for bending or distortion, and replace if evident. Should the boots be dried out, cracked, or distorted, they must be replaced.
  8.  

To install:

  1. Install the constant velocity joint inner race on the axle shaft, and retain with a snapring.
  2.  
  3. Assemble the joint in the opposite order of disassembly.
  4.  
  5. Slide the double offset joint cage onto the shaft, with the counterbore toward the end of the shaft.
  6.  
  7. Install the inner race on the shaft.
  8.  
  9. Install the retaining snapring.
  10.  
  11. Position the cage over the inner race, and fill the cage pockets with grease.
  12.  
  13. Insert the balls into the cage.
  14.  
  15. Fill the well in the outer race with approximately 1 oz. (28 g) grease, and slide the outer race onto the axle shaft.
  16.  
  17. Install the retaining circlip, and add 1 oz. more grease to the interior of the joint. Fill the boot with approximately 1 oz. (28 g), grease, and slide it into position over the double offset joint.
  18.  
  19. Fill the constant velocity joint boot with 3 oz. grease, and install the boot over the joint.
  20.  
  21. Band the boots on both joints tightly enough that they cannot be turned by hand.
  22.  


WARNING
Use only grease specified for use in constant velocity joints.

 
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